EP4001370A1 - Encres aqueuses pour jet d'encre et procédés d'impression à jet d'encre - Google Patents

Encres aqueuses pour jet d'encre et procédés d'impression à jet d'encre Download PDF

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Publication number
EP4001370A1
EP4001370A1 EP20208787.0A EP20208787A EP4001370A1 EP 4001370 A1 EP4001370 A1 EP 4001370A1 EP 20208787 A EP20208787 A EP 20208787A EP 4001370 A1 EP4001370 A1 EP 4001370A1
Authority
EP
European Patent Office
Prior art keywords
pigment
inkjet ink
yellow
aqueous inkjet
pigment yellow
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP20208787.0A
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German (de)
English (en)
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EP4001370C0 (fr
EP4001370B1 (fr
Inventor
Jens Lenaerts
Nadine Willems
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Agfa NV
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Agfa NV
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Filing date
Publication date
Application filed by Agfa NV filed Critical Agfa NV
Priority to EP20208787.0A priority Critical patent/EP4001370B1/fr
Priority to EP21805956.6A priority patent/EP4247907A1/fr
Priority to US18/253,420 priority patent/US20240043709A1/en
Priority to CN202180078210.0A priority patent/CN116568766B/zh
Priority to PCT/EP2021/080911 priority patent/WO2022106236A1/fr
Publication of EP4001370A1 publication Critical patent/EP4001370A1/fr
Application granted granted Critical
Publication of EP4001370C0 publication Critical patent/EP4001370C0/fr
Publication of EP4001370B1 publication Critical patent/EP4001370B1/fr
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D11/00—Inks
    • C09D11/30—Inkjet printing inks
    • C09D11/32—Inkjet printing inks characterised by colouring agents
    • C09D11/322—Pigment inks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
    • B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
    • B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
    • B41J2/01—Ink jet
    • B41J2/21—Ink jet for multi-colour printing
    • B41J2/2107—Ink jet for multi-colour printing characterised by the ink properties
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D11/00—Inks
    • C09D11/30—Inkjet printing inks
    • C09D11/32—Inkjet printing inks characterised by colouring agents
    • C09D11/324—Inkjet printing inks characterised by colouring agents containing carbon black
    • C09D11/326—Inkjet printing inks characterised by colouring agents containing carbon black characterised by the pigment dispersant
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D11/00—Inks
    • C09D11/30—Inkjet printing inks
    • C09D11/40—Ink-sets specially adapted for multi-colour inkjet printing

Definitions

  • Figure 1 shows a cross-section of an embodiment of a decorative panel (1) including, in order, a protective layer (2), an outermost ink receiving layer (3), an inner ink receiving layer (4), a core layer (5) with a tongue (8) and a groove (9) and a balancing layer (7), wherein the one or more ink receiving layers include a jetted and dried colour image (6).
  • alkyl means all variants possible for each number of carbon atoms in the alkyl group i.e. methyl, ethyl, for three carbon atoms: n-propyl and isopropyl; for four carbon atoms: n-butyl, isobutyl and tertiary-butyl; for five carbon atoms: n-pentyl, 1,1-dimethyl-propyl, 2,2-dimethylpropyl and 2-methyl-butyl, etc.
  • a substituted or unsubstituted alkyl group is preferably a C 1 to C 6 -alkyl group.
  • the yellow pigment is C.I. Pigment Yellow 150 or a mixed crystal thereof. It was found that the coloristic properties of C.I. Pigment Yellow 150 were ideal for making true wood colour reproduction in laminate flooring panels, while it was also best in class for light fading of the colour image in decorative panels.
  • the aqueous inkjet ink as claimed preferably contains the yellow pigment in an amount of 2.0 to 5.0 wt% of yellow pigment based on the total weight of the inkjet ink.
  • the pigment in the aqueous inkjet ink preferably has an average particle size as measured by dynamic light scattering between 100 and 200 nm.
  • a pigmented aqueous inkjet ink set comprises: a) a cyan aqueous inkjet ink containing a copper phthalocyanine pigment; b) a red aqueous inkjet ink containing a red pigment selected from the group consisting of C.I. Pigment Red 254, C.I. Pigment Red 122, C.I.
  • an inkjet ink set containing a cyan, red, yellow and black inkjet inks For reproducing wood motifs in the decorative panels, use is made of an inkjet ink set containing a cyan, red, yellow and black inkjet inks.
  • a preferred pigmented aqueous inkjet ink set for manufacturing decorative panels comprises a) a cyan aqueous inkjet ink containing a copper phthalocyanine pigment; b) a red aqueous inkjet ink containing a red pigment selected from the group consisting of C.I. Pigment Red 122, C.I. Pigment Red 176, C.I. Pigment Red 188, C.I. Pigment Red 207, C.I. Pigment Red 242, C.I. Pigment Red 254, C.I. Pigment Red 272 and mixed crystals thereof.
  • the selected pigments in the above ink set are not alone good choices for reproducing wood decorative patterns, but also exhibit good light fastness.
  • the pigment for the red ink is most preferably C.I. Pigment Red 254 or a mixed crystal thereof, most preferably C.I. Pigment Red 254.
  • suitable carbon black pigments are Regal TM 400R, Mogul TM L, Elftex TM 320 from Cabot Co., or Carbon Black FW18, Special Black TM 250, Special Black TM 350, Special Black TM 550, Printex TM 25, Printex TM 35, Printex TM 55, Printex TM 90, Printex TM 150T from EVONIK, MA8 from MITSUBISHI CHEMICAL Co.
  • the black aqueous inkjet ink may include a carbon black pigment and at least one pigment selected from the group consisting of a blue pigment, a cyan pigment, magenta pigment and a red pigment. It was found that such a black inkjet ink allowed easier and better colour management for wood colours, as it produces a more neutral black colour.
  • the average particle size of the pigment in the pigmented inkjet ink should be between 50 nm and 300 nm. Preferably, the average pigment particle size is between 100 and 200 nm. Below an average particle size of 100 nm, a reduction is often observed in light fastness. Above an average particle size of 200 nm, the colour gamut is usually reduced. The colour gamut represents the number of colours that can be produced with a certain inkjet ink set.
  • An anionic polymeric dispersant ID contains ionic groups when present in the inkjet ink at an alkaline pH (pH>7.0). These ionic groups are negatively charged groups, such as dissociated sulfonic acid groups and dissociated carboxylic acid groups. The ionic groups are most preferably dissociated carboxylic acid groups or salts thereof, as these groups interact rapidly with cationic groups present in the one or more ink receiving layers, e.g. from polyvalent metal salts. Such interaction immobilizes the colour pigment on the paper substrate, leading to an improved image quality as coalescence and ink bleeding is minimized.
  • the non-ionic polymeric dispersant contains no or very few ionic groups, preferably it does not contain ionic groups at all. Such non-ionic polymeric dispersant can be identified by determining the acid value.
  • the acid value is defined as the number of mg of potassium hydroxide required to neutralise the free acid groups in 1 g of sample, and can be measured by direct titration with a standard potassium hydroxide solution.
  • the non-ionic polymeric dispersant should preferably have an acid value of no more than 40 mg KOH/g, preferably 0 mg KOH/g.
  • the ionic polymeric dispersant preferably has an acid value of 75 to 250 mg KOH/g, preferably more than 150 mg KOH/g.
  • Preferred anionic polymeric dispersants include carboxylated acrylic copolymers and carboxylated acrylate-styrene copolymers.
  • a particularly preferred carboxylated acrylate-styrene copolymer is Joncryl TM 678 from BASF. It is also available as Joncryl TM 8078 by BASF in a 32% solids ammonia solution of Joncryl TM 678.
  • the polymeric dispersant has preferably a number average molecular weight Mn between 500 and 30000, more preferably between 1500 and 10000.
  • the aqueous inkjet inks may contain at least one surfactant.
  • the surfactant(s) can be anionic, cationic, non-ionic, or zwitter-ionic and are usually added in a total quantity less than 1 wt% based on the total weight of the inkjet ink and particularly in a total quantity less than 0.3 wt% based on the total weight of the inkjet ink.
  • the total quantity above is expressed as dry solids.
  • Suitable surfactants for the aqueous inkjet inks include fatty acid salts, ester salts of a higher alcohol, alkylbenzene sulphonate salts, sulphosuccinate ester salts and phosphate ester salts of a higher alcohol (for example, sodium dodecylbenzenesulphonate and sodium dioctylsulphosuccinate), ethylene oxide adducts of a higher alcohol, ethylene oxide adducts of an alkylphenol, ethylene oxide adducts of a polyhydric alcohol fatty acid ester, and acetylene glycol and ethylene oxide adducts thereof (for example, polyoxyethylene nonylphenyl ether, and SURFYNOL TM 104, 104H, 440, 465 and TG available from AIR PRODUCTS & CHEMICALS INC.).
  • a particularly preferred commercial fluorosurfactant is Capstone TM FS3100 from DU PONT.
  • alkoxylated fluorosurfactant according to Formula (I): wherein
  • R1 to R3 represents hydrogen and R4 represents a methyl group, and more preferably the anionic polar group is a sulfonic acid group or a salt thereof.
  • alkoxylated fluorosurfactants according to Formula (I) are shown in Table 1 .
  • Table 1 FS-1 FS-2 FS-3 FS-4
  • Suitable biocides for the aqueous inkjet inks used in the present invention include sodium dehydroacetate, 2-phenoxyethanol, sodium benzoate, sodium pyridinethion-1-oxide, ethyl p-hydroxybenzoate and 1,2-benzisothiazolin-3-one and salts thereof.
  • Preferred biocides are Proxel TM GXL, Proxel TM K and Proxel TM Ultra 5 available from ARCH UK BIOCIDES and Bronidox TM available from COGNIS.
  • the aqueous inkjet ink preferably contains a humectant.
  • Suitable humectants include triacetin, N-methyl-2-pyrrolidone, 2-pyrrolidone, glycerol, urea, thiourea, ethylene urea, alkyl urea, alkyl thiourea, dialkyl urea and dialkyl thiourea, diols, including ethanediols, propanediols, propanetriols, butanediols, pentanediols, and hexanediols.
  • Preferred humectants are 2-pyrrolidone, glycerol and 1,2-hexanediol, the latter were found to be the most effective for improving inkjet printing reliability in an industrial environment.
  • a humectant is preferably added to the inkjet ink in an amount of 0.1 to 35 wt% of the formulation, more preferably 1 to 30 wt% of the formulation, and most preferably 2 to 25 wt% of the inkjet ink
  • the aqueous inkjet ink may contain at least one pH adjuster.
  • Suitable pH adjusters include NaOH, KOH, NEt 3 , NH 3 , HCI, HNO 3 , H 2 SO 4 and (poly)alkanolamines such as triethanol amine and 2-amino-2-methyl-1-propanol.
  • Preferred pH adjusters are triethanol amine, NaOH and H 2 SO 4 .
  • the pH is preferably adjusted to a value between 7.5 and 10.0, more preferably between 8.0 and 9.0; the latter pH range has been observed to result in an improved ink stability.
  • the above described yellow pigmented inkjet ink containing a combination of a non-ionic polymeric dispersant NID and an anionic polymeric dispersant ID can either be prepared by making the pigment dispersion containing both polymeric dispersants NID and ID, or otherwise only one of them, preferably the non-ionic polymeric dispersant NID. In the latter case, the anionic polymeric dispersant ID is then added during the ink preparation to the pigment dispersion, preferably before adding other ink components.
  • Mixing apparatuses for making pigment dispersions may include a pressure kneader, an open kneader, a planetary mixer, a dissolver, and a Dalton Universal Mixer.
  • Suitable milling and dispersion apparatuses are a ball mill, a pearl mill, a colloid mill, a high-speed disperser, double rollers, a bead mill, a paint conditioner, and triple rollers.
  • the dispersions may also be prepared using ultrasonic energy.
  • the colour ink may be prepared using separate dispersions for each pigment, or alternatively several pigments may be mixed and co-milled in preparing the dispersion.
  • the preferred amounts and ratios of the ingredients of the mill grind will vary widely depending upon the specific materials and the intended applications.
  • the contents of the milling mixture comprise the mill grind and the milling media.
  • the mill grind comprises pigment, dispersant and a liquid carrier such as water.
  • the pigment is usually present in the mill grind at 1 to 50 wt%, excluding the milling media.
  • the weight ratio of pigment over dispersant is preferably 20:1 to 1:2.
  • the pigment dispersion is preferably also filtrated with a filter of 1 ⁇ m, preferably 0.5 ⁇ m to remove so-called 'over-sizers, i.e. inefficiently milled pigment particles having a much larger particle size of 2 ⁇ m or so
  • the colour ink in the form of a concentrated mill grind, which is subsequently diluted to the appropriate concentration for use in the ink-jet printing system.
  • This technique permits preparation of a greater quantity of pigmented ink from the equipment. If the mill grind was made in a solvent, it is diluted with water and optionally other solvents to the appropriate concentration. If it was made in water, it is diluted with either additional water or water miscible solvents to make a mill grind of the desired concentration. By dilution, the ink is adjusted to the desired viscosity, colour, hue, saturation density, and print area coverage for the particular application.
  • a decorative panel illustrated by a flooring panel having also a tongue and groove join in Fig.1 , includes preferably at least a core layer, a decorative layer and a protective layer.
  • a protective layer is applied on top of the decorative layer.
  • a balancing layer may also be applied at the opposite side of the core layer to restrict or prevent possible bending of the decorative panel.
  • the assembly into a decorative panel of the balancing layer, the core layer, the decorative layer, and the protective layer is preferably performed in the same press treatment of preferably a DPL process (Direct Pressure Laminate).
  • tongue and groove profiles are milled into the side of individual decorative panels which allow them to be slid into one another.
  • the tongue and grove join ensures, in the case of flooring panels, a sturdy floor construction and protects the floor, preventing dampness from penetrating.
  • the decorative panels include a tongue and a groove of a special shape, which allow them to be clicked into one another.
  • the advantage thereof is an easy assembly requiring no glue.
  • the shape of the tongue and groove necessary for obtaining a good mechanical join is well-known in the art of laminate flooring, as also exemplified in EP 2280130 A (FLOORING IND), WO 2004/053258 (FLOORING IND), US 2008010937 (VALINGE) and US 6418683 (PERSTORP FLOORING).
  • tongue and groove profiles are especially preferred for flooring panels and wall panels, but in the case of furniture panels, such tongue and groove profile is preferably absent for aesthetical reasons of the furniture doors and drawer fronts.
  • a tongue and groove profile may be used to click together the other panels of the furniture, as illustrated by US 2013071172 (UNILIN).
  • the decorative panels may further include a sound-absorbing layer as disclosed by US 8196366 (UNILIN).
  • the decorative panel is an antistatic layered panel.
  • Techniques to render decorative panels antistatic are well-known in the art of decorative surfaces as exemplified by EP 1567334 A (FLOORING IND).
  • the decorative flooring panels are made in the form of rectangular oblong strips.
  • the dimensions thereof may vary greatly.
  • the panels have a length exceeding 1 meter, and a width exceeding 0.1 meter, e.g. the panels can be about 1.3 meter long and about 0.15 meter wide.
  • the length of the panels exceeds 2 meter, with the width being preferably about 0.2 meter or more.
  • the print of such panels is preferably free form repetitions.
  • the core layer is preferably made of wood-based materials, such as particle board, MDF or HDF (Medium Density Fibreboard or High Density Fibreboard), Oriented Strand Board (OSB) or the like. Use can also be made of boards of synthetic material or boards hardened by means of water, such as cement boards. In a particularly preferred embodiment, the core layer is a MDF or HDF board.
  • MDF or HDF Medium Density Fibreboard or High Density Fibreboard
  • OSB Oriented Strand Board
  • the core layer comprises a foamed synthetic material, such as foamed polyethylene or foamed polyvinyl chloride.
  • the thickness of the core layer is preferably between 2 and 12 mm, more preferably between 5 and 10 mm.
  • the decorative layer and preferably also the protective layer and the optional balancing layer, include paper as substrate.
  • the paper sheets have a porosity according to Gurley's method (DIN 53120) of between 8 and 20 seconds.
  • Gurley's method DIN 53120
  • Such porosity allows even for a heavy sheet of more than 150 g/m 2 to be readily impregnated with a relatively high amount of resin.
  • Suitable paper sheets having high porosity and their manufacturing are also disclosed by US 6709764 (ARJO WIGGINS).
  • the paper for the decorative layer is preferably a bulk coloured paper including one or more colour dyes and/or colour pigments.
  • a coloured paper reduces the amount of inkjet ink required to print the colour image.
  • a light brown or grey paper may be used for printing a wood motif as colour image in order to reduce the amount of inkjet ink needed.
  • unbleached Kraft paper is used for a brownish coloured paper in the decorative layer.
  • Kraft paper has a low lignin content resulting in a high tensile strength.
  • a preferred type of Kraft paper is absorbent Kraft paper of 40 to 135 g/m 2 having high porosity, and made from clean low kappa hardwood Kraft of good uniformity.
  • the protective layer includes a paper
  • a paper is used which becomes transparent or translucent after resin impregnation so that the colour image in the decorative layer can be viewed.
  • One or more ink receiving layers are present on the paper substrate of the decorative layer for enhancing the image quality.
  • the ink receiving layer(s) may be a purely polymer based ink receiving layer, but preferably contains an inorganic pigment and a polymeric binder.
  • the inorganic pigment may be a single type of inorganic pigment or a plurality of different inorganic pigments.
  • the polymeric binder may be a single type of polymeric binder or a plurality of different polymeric binders.
  • the ink receiving layer(s) include a polymeric binder selected from the group consisting of hydroxyethyl cellulose; hydroxypropyl cellulose; hydroxyethylmethyl cellulose; hydroxypropyl methyl cellulose; hydroxybutylmethyl cellulose; methyl cellulose; sodium carboxymethyl cellulose; sodium carboxymethylhydroxethyl cellulose; water soluble ethylhydroxyethyl cellulose; cellulose sulfate; polyvinyl alcohol; vinylalcohol copolymers; polyvinyl acetate; polyvinyl acetal; polyvinyl pyrrolidone; polyacrylamide; acrylamide/acrylic acid copolymer; polystyrene, styrene copolymers; acrylic or methacrylic polymers; styrene/acrylic copolymers; ethylene-vinylacetate copolymer; vinyl-methyl ether/maleic acid copolymer; poly(2-acrylamid
  • the ink receiving layer(s) include a polymeric binder, preferably a water soluble polymeric binder (> 1 g/L water at 25°C), which has a hydroxyl group as a hydrophilic structural unit, e.g. a polyvinyl alcohol.
  • a preferred polymer for the ink receiving layer(s) is a polyvinylalcohol (PVA), a vinylalcohol copolymer or modified polyvinyl alcohol.
  • the modified polyvinyl alcohol may be a cationic type polyvinyl alcohol, such as the cationic polyvinyl alcohol grades from Kuraray, such as POVAL C506, POVAL C118 from Nippon Goshei.
  • the pigment in the ink receiving layer(s) is an inorganic pigment, which can be chosen from neutral, anionic and cationic pigment types.
  • Useful pigments include e.g. silica, talc, clay, hydrotalcite, kaolin, diatomaceous earth, calcium carbonate, magnesium carbonate, basic magnesium carbonate, aluminosilicate, aluminum trihydroxide, aluminum oxide (alumina), titanium oxide, zinc oxide, barium sulfate, calcium sulfate, zinc sulfide, satin white, alumina hydrate such as boehmite, zirconium oxide or mixed oxides.
  • the inorganic pigment is preferably selected from the group consisting of alumina hydrates, aluminum oxides, aluminum hydroxides, aluminum silicates, and silicas.
  • Particularly preferred inorganic pigments are silica particles, colloidal silica, alumina particles and pseudo-boehmite, as they form better porous structures.
  • the particles may be primary particles directly used as they are, or they may form secondary particles.
  • the particles Preferably, the particles have an average primary particle diameter of 2 ⁇ m or less, and more preferably 200 nm or less.
  • ⁇ -Al(OH) 3 such as PLURAL BT, available from Sasol, and Gibbsite, or ⁇ -Al(OH) 3 , such as MARTINAL grades and MARTIFIN grades from Martinswerk GmbH , MICRAL grades from JM Huber company; HIGILITE grades from Showa Denka K.K..
  • Useful types include AEROSIL OX50 (BET surface area 50 ⁇ 15 m 2 /g, average primary particle size 40 nm, SiO 2 content > 99.8%, Al 2 O 3 content ⁇ 0.08%), AEROSIL MOX170 (BET surface area 170 g/m 2 , average primary particle size 15 nm, SiO 2 content > 98.3%, Al 2 O 3 content 0.3-1.3%), AEROSIL MOX80 (BET surface area 80 ⁇ 20 g/m 2 , average primary particle size 30 nm, SiO 2 content > 98.3%, Al 2 O 3 content 0.3-1.3%), or other hydrophilic AEROSIL grades available from Degussa-Hüls AG, which may give aqueous dispersions with a small average particle size ( ⁇ 500 nm).
  • AEROSIL OX50 BET surface area 50 ⁇ 15 m 2 /g, average primary particle size 40 nm, SiO 2 content > 99.8%, Al 2 O 3
  • silica particles are grouped into two types, wet-process particles and dry-process (vapour phase-process or fumed) particles.
  • active silica is formed through acidolysis of silicates, and this is polymerized to a suitable degree and flocculated to obtain hydrous silica.
  • a vapour-phase process includes two types; one includes high-temperature vapour-phase hydrolysis of silicon halide to obtain anhydrous silica (flame hydrolysis), and the other includes thermal reduction vaporization of silica sand and coke in an electric furnace followed by oxidizing it in air to also obtain anhydrous silica (arc process).
  • the "fumed silica” means to indicate anhydrous silica particles obtained in the vapour-phase process.
  • said ink receiving layer can be further crosslinked.
  • Any suitable crosslinker known in the prior art can be used. Boric acid is particularly preferred as crosslinker for the ink receiving layer according to the present invention.
  • the ink receiving layer(s) may include other additives, such as colorants, surfactants, biocides, antistatic agents, hard particles for wear resistance, elastomers, UV absorbers, organic solvents, plasticizers, light-stabilizers, pH adjusters, antistatic agents, whitening agents, matting agents and the like.
  • additives such as colorants, surfactants, biocides, antistatic agents, hard particles for wear resistance, elastomers, UV absorbers, organic solvents, plasticizers, light-stabilizers, pH adjusters, antistatic agents, whitening agents, matting agents and the like.
  • the ink receiving layer(s) may consist of a single layer or of two, three or more layers even having a different composition.
  • the ink receiving layer(s) can also be applied just prior to inkjet printing by applying a primer to uncoated standard decor paper.
  • thermosetting resin is preferably selected from the group consisting of melamine-formaldehyde based resins, ureum-formaldehyde based resins and phenol-formaldehyde based resins.
  • thermosetting resin is a melamine-formaldehyde based resin, often simply referred to in the art as a 'melamine (based) resin'. It has been observed that such melamin based thermosetting resin is the most transparent having the least impact on the colour strength, especially when used in the protective layer..
  • the melamine formaldehyde resin preferably has a formaldehyde to melamine ratio of 1.4 to 2.
  • Such melamine based resin is a resin that polycondensates while exposed to heat in a pressing operation.
  • the polycondensation reaction creates water as a by-product. It is particularly with these kinds of thermosetting resins, namely those creating water as a by-product, that the present invention is of interest.
  • the created water, as well as any water residue in the thermosetting resin before the pressing must leave the hardening resin layer to a large extent before being trapped and leading to a loss of transparency in the hardened layer.
  • the available ink layer can hinder the diffusion of the vapour bubbles to the surface, resulting in adhesion problems.
  • the paper is preferably provided with an amount of thermosetting resin equalling 40 to 250% dry weight of resin as compared to weight of the paper.
  • this range of applied resin provides for a sufficient impregnation of the paper, that avoids splitting to a large extent, and that stabilizes the dimension of the paper to a high degree.
  • the paper is preferably provided with such an amount of thermosetting resin, that at least the paper core is satisfied with the resin. Such satisfaction can be reached when an amount of resin is provided that corresponds to at least 1.5 or at least 2 times the paper weight.
  • the resin provided on said paper is in a B-stage while printing.
  • Such B-stage exists when the thermosetting resin is not completely cross linked.
  • the step of providing said paper with thermosetting resin involves applying a mixture of water and the resin on the paper.
  • the application of the mixture might involve immersion of the paper in a bath of the mixture and/or spraying or jetting the mixture.
  • the resin is provided in a dosed manner, for example by using one or more squeezing rollers and/or doctor blades to set the amount of resin added to the paper layer.
  • VITS Methods for impregnating a paper substrate with resin are well-known in the art as exemplified by WO 2012/126816 (VITS) and EP 966641 A (VITS).
  • the dry resin content of the mixture of water and resin for impregnation depends on the type of resin.
  • An aqueous solution containing a phenol-formaldehyde resin preferably has a dry resin content of about 30% by weight, while an aqueous solution containing a melamine-formaldehyde resin preferably has a dry resin content of about 60% by weight.
  • Methods of impregnation with such solutions are disclosed by e.g. US 6773799 (DECORATIVE SURFACES).
  • the paper is preferably impregnated with the mixtures known from US 4109043 (FORMICA CORP) and US 4112169 (FORMICA CORP) , and hence preferably comprise, next to melamine formaldehyde resin, also polyurethane resin and/or acrylic resin.
  • the mixture including the thermosetting resin may further include additives, such as colorants, surface active ingredients, biocides, antistatic agents, hard particles for wear resistance, elastomers, UV absorbers, organic solvents, acids, bases, and the like.
  • additives such as colorants, surface active ingredients, biocides, antistatic agents, hard particles for wear resistance, elastomers, UV absorbers, organic solvents, acids, bases, and the like.
  • the advantage of adding a colorant to the mixture containing the thermosetting resin is that a single type of white paper can be used for manufacturing the decorative layer, thereby reducing the stock of paper for the decorative laminate manufacturer.
  • the use of a colored paper, as already described above, to reduce the amount of ink required for printing a wood motif, is here accomplished by the white paper being colored by impregnation by a brownish thermosetting resin. The latter allows a better control of the amount of brown colour required for certain wood motifs.
  • Antistatic agents may be used in thermosetting resin. However preferably antistatic agents, like NaCl and KCI, carbon particles and metal particles, are absent in the resin, because often they have undesired side effects such as a lower water resistance or a lower transparency. Other suitable antistatic agents are disclosed by EP 1567334 A (FLOORING IND).
  • Hard particles for wear resistance are preferably included in a protective layer.
  • the decorative layer includes a thermosetting resin impregnated paper and a colour image printed thereon by inkjet.
  • the colour image is located on the resin impregnated paper on the opposite side than the side facing the core layer.
  • a decorative panel like a floor panel, has on one side of the core layer a decorative layer and a balancing layer on the other side of the core layer.
  • a decorative layer may be applied on both sides of the core layer. The latter is especially desirable in the case of laminate panels for furniture.
  • a protective layer is applied on both decorative layers present on both sides of the core layer.
  • a multi-colour image is obtained by jetting and drying aqueous inkjet inks of an aqueous inkjet ink set upon the one or more ink receiving layers.
  • the colour image may also contain information such as text, arrows, logo's and the like.
  • the advantage of inkjet printing is that such information can be printed at low volume without extra cost, contrary to gravure printing.
  • the colour image is a wood reproduction or a stone reproduction, but it may also be a fantasy or creative image, such as an ancient world map or a geometrical pattern, or even a single colour for making, for example, a floor consisting of black and yellow tiles or a single colour furniture door.
  • An advantage of printing a stone colour image is that a floor can be manufactured which is an exact imitation of a stone floor, but without the cold feeling when walking barefooted on it.
  • a protective layer is applied above the printed colour image after printing, e.g. by way of an overlay, i.e. a resin provided carrier, or a liquid coating, preferably while the decor layer is laying on the core layer, either loosely or already connected or adhered thereto.
  • an overlay i.e. a resin provided carrier, or a liquid coating
  • the carrier of the overlay is a paper impregnated by a thermosetting resin that becomes transparent or translucent after heat pressing, preferably in a DPL process.
  • the liquid coating includes preferably a thermosetting resin, but may also be another type of liquid such as a UV- or an EB-curable varnish.
  • the protective layer is preferably the outermost layer, but in another embodiment a thermoplastic or elastomeric surface layer may be coated on the protective layer, preferably of pure thermoplastic or elastomeric material. In the latter case, preferably a thermoplastic or elastomeric material based layer is also applied on the other side of the core layer.
  • Liquid melamine coatings are exemplified in DE 19725289 C (ITT MFG ENTERPRISES) and US 3173804 (RENKL PAIDIWERK).
  • the liquid coating may contain hard particles, preferably transparent hard particles.
  • Suitable liquid coatings for wear protection containing hard particles and methods for manufacturing such a protective layer are disclosed by US 2011300372 (CT FOR ABRASIVES AND REFRACTORIES) and US 8410209 (CT FOR ABRASIVES AND REFRACTORIES).
  • the total quantity of hard particles and transparent solid material particles is typically between 5% by volume and 70% by volume, based on the total volume of the liquid coating.
  • the total quantity of hard particles is between 1 g/m 2 and 100 g/m 2 , preferably 2 g/m 2 to 50 g/m 2 .
  • the amount of hard particles in the protective layer may be determined in function of the desired wear resistance, preferably by a so-called Taber test as defined in EN 13329 and also disclosed in WO 2013/050910 A (UNILIN) and US 8410209 (CT FOR ABRASIVES AND REFRACTOR).
  • the step of providing the protective layer of thermosetting resin above the printed image involves a press treatment.
  • a temperature above 150°C is applied in the press treatment, more preferably between 180° and 220°C, and a pressure of more than 20 bar, more preferably between 35 and 40 bar.
  • An alternative advantage of using at least two press treatments lays in the fact that a similar wearing rate, as in the case where a single press treatment is used, can be obtained with less hard particles if the product is pressed twice. Lowering the amount of hard particles is interesting, since hard particles tend to lower the transparency of the wear resistant protective layer, which is undesirable. It becomes also possible to work with hard particles of smaller diameter, e.g. particles having an average particle diameter of 15 ⁇ m or less, or even of 5 ⁇ m or less.
  • the main purpose of the balancing layer(s) is to compensate tensile forces by layers on the opposite side of the core layer, so that an essentially flat decorative panel is obtained.
  • a balancing layer is preferably a thermosetting resin layer, that can comprise one or more carrier layers, such as paper sheets.
  • the balancing layer(s) may be a decorative layer, optionally complemented by a protective layer.
  • an opaque balancing layer may be used which gives the decorative panel a more appealing look by masking surface irregularities. Additionally, it may contain text or graphical information such as a company logo or text information.
  • An inkjet printing method for manufacturing decorative panels comprising the steps of a) providing a paper substrate including one or more ink receiving layers; b) jetting a colour image with pigmented aqueous inkjet inks from the pigmented aqueous inkjet ink set as described above on the paper substrate including one or more ink receiving layers; and c) drying the jetted colour image.
  • the application of ink receiving layers on the paper substrate allow to achieve a desired image quality without the need of a polymer latex binder in the aqueous inkjet inks.
  • the presence of polymer latex binder usually reduces the adhesion of the protective layer to the decorative layer.
  • no polymer latex binder is present in one or more of the aqueous pigmented inkjet inks, preferably none of the pigmented aqueous inkjet inks contain a polymeric latex binder.
  • the inkjet printing method is preferably performed in a multi-pass mode.
  • the jetting of the colour image by the inkjet print heads is performed in 2, 3, 4 or more passes, the presence of failing nozzles can be masked to a level wherein it becomes no longer visible that a nozzle is not firing inkjet ink. The latter is usually immediately visible in a single pass inkjet printing process, thus creating substantial amount of waste and economic penalties.
  • the paper substrate includes multiple ink receiving layers, wherein an outermost ink receiving layer contains no inorganic pigment or an amount of inorganic pigment smaller than that of the one or more ink receiving layers located between the paper substrate and the outermost ink receiving layer.
  • the ink receiving layers contain high amounts of inorganic pigments, such as microporous silica, which can create dust problems due to the transporting of the paper substrate in the inkjet printer, especially in a single pass inkjet printing pass where very high speeds for transporting the paper substrate below the print heads are used. This dust problem is reduced by having an outermost ink receiving layer containing no or only a small amount of inorganic pigments.
  • the paper substrate is a coloured paper substrate, more preferably a bulk coloured paper substrate.
  • a coloured paper substrate reduces the amount of inkjet ink required to form the colour image.
  • the one or more ink receiving layers include an inorganic pigment selected from the group consisting of alumina hydrates, aluminum oxides, aluminum hydroxides, aluminum silicates, and silicas.
  • an inorganic pigment selected from the group consisting of alumina hydrates, aluminum oxides, aluminum hydroxides, aluminum silicates, and silicas. The latter inorganic pigments allow for fast drying and high image quality.
  • the one or more ink receiving layers contain a polymeric binder selected from the group consisting of polyvinylalcohol, a vinylalcohol copolymer or modified polyvinyl alcohol.
  • a polymeric binder selected from the group consisting of polyvinylalcohol, a vinylalcohol copolymer or modified polyvinyl alcohol.
  • the latter polymeric binders are very hydrophilic and allow fast penetration of the liquids in the aqueous inkjet inks, again enhancing drying and high image quality.
  • the viscosity of the one or more aqueous inkjet inks at a temperature of 32°C is preferably smaller than 15 mPa.s, and most preferably between 4 and 8 mPa.s all at a shear rate of 1,000 s -1 .
  • the jetting temperature is between 10 and 70°C, preferably between 20 and 40°C, and most preferably between 25 and 38°C. In those ranges printing reliability is enhanced due to improved latency, as the evaporation of the liquid components in the inkjet inks at the nozzle of a print head is limited.
  • the paper substrate having the jetted and dried colour image is impregnated with a thermosetting resin.
  • the impregnated paper substrate is heat pressed between a core layer and a protective layer and cut into a decorative panel selected from the group consisting of flooring, kitchen, furniture and wall panels.
  • the protective layer preferably includes a melamine-based thermosetting resin.
  • the decorative panel includes a tongue and a groove capable of achieving a glue less mechanical join between decorative panels.
  • the inkjet printing method of the invention is part of a DPL process, wherein the decorative layer is taken up in a stack to be pressed with the core layer and a protective layer, and preferably also a balancing layer.
  • the method of the invention would form part of a CPL (Compact Laminate) or an HPL (High Pressure Laminate) process in which the decorative layer is hot pressed at least with a plurality of resin impregnated core paper layers, e.g.
  • thermosetting resin may be a colored thermosetting resin to reduce the amount of inkjet ink to be printed.
  • the method of manufacturing a decorative surface preferably includes providing a relief in at least the protective layer, more preferably by means of a short cycle embossing press.
  • the embossing preferably takes place at the same time that the core layer, the decorative layer and the protective layer, and preferably also one or more balancing layers, are pressed together.
  • the relief in the protective layer preferably corresponds to the colour image.
  • the relief comprises portions that have been embossed over a depth of more than 0.5 mm, or even more than 1 mm, with respect to the global upper surface of the decorative panel.
  • the embossments may extend into the decorative layer.
  • the balancing layer of a decorative panel is preferably planar. However, a relief might be applied in the balancing layer(s) for improving gluing down of the panels and/or for improved slip resistance and/or for improved, i.e. diminished, sound generation or propagation.
  • any panel that comprises on the one hand a wear resistant protective layer on the basis of a thermosetting synthetic material, possibly a carrier sheet such as paper, and hard particles, and, on the other hand, one or more layers underlying the wear resistant protective layer on the basis of thermosetting synthetic material.
  • the underlying layers may comprise a decorative layer, such as an inkjet printed paper provided with thermosetting resin.
  • a core layer such panel might essentially comprise a board material with a density of more than 500 kg/m 3 , such as an MDF or HDF board material.
  • the manufacturing panels with a plurality of press treatments is preferably put in practice with the so-called DPL panels (Direct Pressure Laminate).
  • DPL panels Direct Pressure Laminate
  • the decorative layer provided with thermosetting resin is cured and attached to the core material, preferably an MDF or HDF board material, whereby a whole is obtained of at least the decorative layer and the board material, and possibly a balancing layer at the side of the board opposite the decor layer.
  • the wear resistant layer is cured and attached to the obtained whole.
  • the method for manufacturing a decorative surface uses the inkjet printing method according to the present invention in combination with the methodology disclosed by US 2011008624 (FLOORING IND), wherein the protective layer includes a substance that hardens under the influence of ultraviolet light or electron beams.
  • the one or more aqueous inkjet inks may be jetted by one or more print heads ejecting small droplets in a controlled manner through nozzles onto a substrate, which is moving relative to the print head(s).
  • a preferred print head for the inkjet printing system is a piezoelectric head.
  • Piezoelectric inkjet printing is based on the movement of a piezoelectric ceramic transducer when a voltage is applied thereto. The application of a voltage changes the shape of the piezoelectric ceramic transducer in the print head creating a void, which is then filled with ink. When the voltage is again removed, the ceramic expands to its original shape, ejecting a drop of ink from the print head.
  • the inkjet printing method according to the present invention is not restricted to piezoelectric inkjet printing.
  • Other inkjet print heads can be used and include various types, such as a continuous type.
  • the inkjet print head scans back and forth in a transversal direction across the moving ink-receiver surface. Sometimes the inkjet print head does not print on the way back. Bidirectional printing is preferred for obtaining a high area throughput.
  • Another preferred printing method is by a "single pass printing process", which can be performed by using page wide inkjet print heads or multiple staggered inkjet print heads which cover the entire width of the ink-receiving surface. In a single pass printing process the inkjet print heads usually remain stationary and the substrate surface is transported under the inkjet print heads.
  • a preferred drying device uses Carbon Infrared Radiation (CIR) to heat the outside of the paper substrate quickly.
  • CIR Carbon Infrared Radiation
  • NIR-radiation energy quickly enters into the depth of the inkjet ink layer and removes water and solvents out of the whole layer thickness, while conventional infrared and thermo-air energy predominantly is absorbed at the surface and slowly conducted into the ink layer, which results usually in a slower removal of water and solvents.
  • An effective infrared radiation source preferably has an emission maximum between 0.8 and 1.5 ⁇ m.
  • Such an infrared radiation source is sometimes called a NIR dryer.
  • the NIR radiation source is in the form of NIR LEDs, which can be mounted easily on a shuttling system of a plurality of inkjet print heads in a multi-pass inkjet printing device.
  • the viscosity of an inkjet ink was measured, using a Brookfield DV-II+ viscometer at 32°C at a shear rate of 1,000 s -1 .
  • An ink sample is diluted with water to a pigment concentration of 0.002 wt%.
  • the average particle size of pigment particles is determined with a Nicomp TM 30 Submicron Particle Analyzer based upon the principle of dynamic light scattering.
  • the average particle size of the dispersed particles is preferably below 250 nm.
  • the inkjet ink is considered a stable pigment dispersion if the average particle size does not increase by more than 20 % after a heat treatment of 1 week at 60°C.
  • the inkjet ink is considered a stable pigment dispersion if viscosity does not increase by more than 20 % after a heat treatment of 1 week at 60°C.
  • the reflectance spectrum of a sample was measured three times with a Gretag TM SPM50 spectrophotometer in the range from 380 up to 730 nm in steps of 10 nm.
  • the the CIE L* a* b* coordinates were determined for a 2° observer and a D50 light source.
  • a meaningful improvement in colour saturation by the inkjet ink is an increase in chroma C* of at least 10%.
  • the optical density was measured using a Gretag TM SPM50 spectrophotometer.
  • a meaningful improvement in colour saturation by the inkjet ink is an increase in optical density ( ⁇ %) of at least 15%.
  • the ink stability was tested for each inkjet ink by comparing the viscosity and the average particle size with that measured after a heat treatment of 1 week at 60°C ( ⁇ %).
  • the ink stability was tested for each inkjet ink by comparing the viscosity and the average particle size with that measured after a heat treatment of 1 week at 60°C ( ⁇ %).
  • a CRYK inkjet ink set was formed by combining the yellow inkjet ink INV-1 with the inkjet inks C, R and K.
  • the inkjet inks COMP-1 and INV-1 were coated with a bar coater on an IJTP paper at a wet layer thickness of 6 ⁇ m. After coating, the ink layers were dried for 2 min at 60°C. Both coated samples were then impregnated and heat pressed in the same manner as the inkjet printed images. It was observed that the improved colour saturation of INV-1 versus COMP-1 was still present after resin impregnation and heat pressing.

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  • Chemical & Material Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Inks, Pencil-Leads, Or Crayons (AREA)
  • Ink Jet Recording Methods And Recording Media Thereof (AREA)
EP20208787.0A 2020-11-20 2020-11-20 Encres aqueuses pour jet d'encre et procédés d'impression à jet d'encre Active EP4001370B1 (fr)

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EP20208787.0A EP4001370B1 (fr) 2020-11-20 2020-11-20 Encres aqueuses pour jet d'encre et procédés d'impression à jet d'encre
EP21805956.6A EP4247907A1 (fr) 2020-11-20 2021-11-08 Encres aqueuses pour jet d'encre et procédés d'impression au jet d'encre
US18/253,420 US20240043709A1 (en) 2020-11-20 2021-11-08 Aqueous Inkjet Inks and Inkjet Printing Methods
CN202180078210.0A CN116568766B (zh) 2020-11-20 2021-11-08 水性喷墨油墨和喷墨印刷方法
PCT/EP2021/080911 WO2022106236A1 (fr) 2020-11-20 2021-11-08 Encres aqueuses pour jet d'encre et procédés d'impression au jet d'encre

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